9U-7500 Transmission Analyzer II{3030, 0783} Caterpillar

Introduction

The 9U-7500 Transmission Analyzer II shifts electronically-controlled AVSpare transmissions. These include the Powershift planetary, the Powershift countershaft, the ICM (Individual Clutch Modulation), the Challenger tractor, the H-Series Motor Grader, and the ECPC (Electronic Clutch Pressure Control) transmissions. The analyzer controls these transmissions by replacing the vehicle harness and the electronic transmission controls that are onboard the vehicle. This allows the technician to check AVSpare transmissions on the hydraulic test bench, independent of the vehicle.

The following features are contained in the Transmission Analyzer II:

* Easy to read menus, on a lighted LCD display, step the operator through the sequence of operating the Transmission Analyzer II. It performs three different transmission system functions; checks solenoid condition, shifts the transmission, and checks shift lever operation.

* Analyzer is controlled by an Intel microprocessor with Flash memory, so the analyzer can be easily updated to new types of transmissions.

* Connects directly to the solenoids of an electronically shifted AVSpare transmission.

* Outputs PWM (Pulse Width Modulated) current to the initialized solenoids, as required by Challenger and Electronic Clutch Pressure Control transmissions.

* Capable of turning on solenoids in a timeline sequence, as required for the H-Series Motor Grader. It is also capable of modulating current to one, or all, of the initialized solenoids at any point in time.

* Performs automatic or manual testing for shorted, and open solenoid coils, on all or any one of the transmission solenoids. The analyzer will also alert you to an intermittent problem with the solenoid coil.

* Checks the shift lever to make sure it is functioning properly, on a transmission that is not controlled by the Autoshift electronic transmission control feature.

Machine Model List

List of current machines that the 9U-7500 Transmission Analyzer II will support. Future machines will be added through the NETG5021, Annual Subscription, as they become available.

Parts

9U-7500 Transmission Analyzer Group

9U-7500 Transmission Analyzer Group. Refer to Chart B for item identifications and description.

Optional Parts

Optional parts used with the 9U-7500 Transmission Analyzer Group.

Specifications

Nomenclature

Front Panel

9U-7500 Transmission Analyzer.
(1) Keypad. (2) PROG PORT. (3) TEST CABLE port. (4) DC power connection. (5) DC power switch. (6) AC power connection. (7) AC power switch. (8) Display.

Enlarged view of keypad (1).

1. Keypad

FWD-Selects forward direction after gear number is selected.

N-Press this key to go to Neutral from any gear.

REV-Selects reverse direction after gear number is selected.

ENTER-Enters the selected command.

CLEAR-Erases a selected command or clears a fault that occurs during solenoid testing.

Cursor-These arrow keys move the cursor on the LCD screen to select the preferred menu object.

MAIN MENU-Selects a list of machine families to choose from.

MACH INFO-Selects the last machine worked on and lists descriptive data for that transmission.

SHIFT LEVER TEST-Tests shift levers on non-Autoshift transmissions.

XMSN TEST-In Transmission Test mode, shifts the transmission to any gear.

SOL TEST-In Solenoid Test mode, checks the condition of the solenoids or turns individual solenoids on one at a time.

NUMERIC KEYS-Enter the numbers asked for by the Transmission Analyzer II program, and enter the gear numbers when shifting.

2. PROG PORT

Plug serial communication cable into connector to program Flash memory.

3. TEST CABLE

Transmission test cable is plugged into this connector.

4. DC POWER

External DC power cable installs in this connector when using battery power or some other external DC power source.

5. DC Power Switch

Turns DC power ON and OFF and protects against DC power overloads.

6. AC POWER

External AC power cable is to be plugged into this connector when using utility power to power analyzer.

7. AC POWER SWITCH

Turns AC power ON and OFF and protects against AC power overloads.

8. DISPLAY

Four line/20 Character LCD display.

Operation

Adjusting Screen Contrast

To adjust the contrast of the LCD display:

1. Press the up and down arrow keys at the same time.

2. This screen will appear:

3. Adjust the contrast to the desired level.

4. Press the "ENTER" key, to return to normal operation.

Power

Operating on 240 Volts AC

The 9U-7500 Transmission Analyzer II can be powered from either 110 or 240 VAC 50/60 Hz. It comes from the factory with a line cord which has a U.S. 120 VAC, 60 Hz plug. To power it with 240 Volt AC, remove (cut-off) the 120 Volt AC plug and install a new 240 Volt AC plug.

Power Requirements for Challenger Transmissions

The Challenger 35, 45, and 55 Tractors need more power to operate their solenoids than other AVSpare transmissions. To use the 9U-7500 Transmission Analyzer II on these transmissions, a larger power source must be supplied to the Analyzer.

Two different DC power sources are available for the transmission analyzer. First, a 12 Volt battery and the DC power connection with the DC power cable supplied with the unit can be used. Second, a DC power supply with filtered output that is capable of supplying 12 VDC at 20 Amps, can be used. This is a large power supply and can be quite expensive to purchase. Do not use a battery charger of any type to power the transmission analyzer.

Operating Instructions

With the engine turned OFF, the Transmission Analyzer II can be used in the Solenoid Test or Shift Lever Test modes with the transmission mounted on or off the machine.

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To use the Transmission Analyzer II in the Transmission Test mode, which shifts the transmission, the transmission must be mounted on a Hydraulic Test Stand. DO NOT SHIFT THE TRANSMISSION WHILE THE TRANSMISSION IS STILL IN THE MACHINE.

To test ICM (Individual Clutch Modulation) style transmissions, refer to "Using the Analyzer with ICM Transmissions" section.

1. Turn Transmission Analyzer II ON using the AC Power switch on the front panel. If using external DC power, turn the analyzer ON by turning ON the DC Power switch on the front panel.

a. This first screen appears momentarily.

b. This second screen then appears momentarily. It shows the Serial Number, Version Number, and Version Date.

c. The third screen to appear is the "Main Menu" screen.

2. Move cursor, using arrow keys on keyboard, to select machine family, and press "ENTER".

a. The up and down arrows on the screen, show that there are more machines available by pressing the up and down arrow keys.

b. TOOL CARRIERS have been selected in this example.

3. Move cursor, using arrow keys on keyboard, to select machine number, and press "ENTER". The IT12 INTEGRATED TOOL CARRIER was selected in this example.

4. This screen should now appear. It is called the "Machine Information" screen.

a. Verify that the information on this screen is for the transmission selected for the test.

b. From this screen any of the following tests can be selected.

SOLENOID TEST

AUTOMATIC

MANUAL

etc.

GEAR SELECTOR TEST

TRANSMISSION SHIFT TEST

Checking Analyzer For Proper Operation

The Transmission Shift Analyzer II has the capability of testing its own operation. This can be done by entering the unit's self-diagnostic test mode. To enter the self-diagnostic mode, use the following procedure.

1. Make sure the "MACH INFO" screen is active.

2. Press and hold down the "REV" and "FWD" keys at the same time.

3. This diagnostics menu will appear:

4. Press a number key to select the appropriate test.

5. If the "LOGIC TEST" is selected, the analyzer will perform a diagnostic test to check the RAM, EEPROM, Analog - Digital Converter, and Flash Memory.

6. If an error occurs during this test, one of the following error messages will be displayed.

RAM Fault

EEPROM Fault

ADC Fault

Flash Mem Fault

7. If one of the errors is displayed, the unit should be returned to AVSpare Service Technology for repair.

8. If the "DISPLAY TEST" is selected, these choices will appear on the display.

a. The "SCROLL SCREEN" moves characters across the screen for a few seconds. If the characters do not appear correctly, return analyzer to AVSpare Service Technology for repair.

b. The "TEST CONTRAST" will adjust the contrast of the display up and down six times. If the contrast does not appear to be functional, return analyzer to AVSpare Service Technology for repair.

c. The "TEST BACKLIGHT" will blink the backlight ON and OFF to check the backlight operation. If the backlight does not appear to be functioning, return analyzer to AVSpare Service Technology for repair.

d. The "EXIT DISPLAY TEST" will exit the "DISPLAY TEST" mode.

9. If the "TEST 24V SUPPLY" is selected, the analyzer will check the supply voltage to make sure the 24 Volt internal power supply is operating correctly. The display will show the voltage reading. If the reading is too high or too low, an error message will appear. If an error occurs, return the analyzer to AVSpare Service Technology for repair.

10. If the "INPUT/OUTPUT TEST" is selected this screen will appear

a. The "TEST CURRENTS" selection performs a test on the input pins of the "TEST CABLE" connector, testing a current level that is produced by the analyzer.

To perform this test, all test cables must be removed.

If there is no error, the analyzer will return to the test screen when the test is complete. If the current is outside the specified limits, the test will stop and an error will be displayed on the screen.

To continue the test, press the "CLEAR" key. If an error occurs, return transmission analyzer to AVSpare Service Technology for repair.

b. The "TEST I/O" selection will test the voltage levels of each pin of the "TEST CABLE" connector.

To perform this test, all test cables must be removed. The test will verify that the outputs to the pins are going high and low when they are commanded to do so. It will also check that no outputs are shorted together or to ground.

c. The "EXIT TEST" will exit the "INPUT/OUTPUT TEST" mode.

11. If all the tests are acceptable (no errors) return to the DIAGNOSTICS MENU and press CLEAR to return to normal operation.

Updating The Program

1. To keep the Transmission Analyzer II up-to-date with the latest transmissions, there is a NETG5021 Software Subscription available from AVSpare.

2. After receiving the NETG5021 Software from AVSpare (3 1/2 inch floppy disk), initialize your computer. Put the floppy disk in your computer's disk drive.

3. Connect a 1U-9484 Serial Communications Cable between the computer's RS-232C serial port and the PROG PORT on the unit.

4. Operate your computer in DOS Mode.

5. To run the Flash program, type: "flash.bat" at the DOS A:\prompt.

6. Follow the step-by-step instructions in the Flash program.

7. After completing the Flash program instructions, turn the Transmission Analyzer II OFF.

8. Disconnect the programming cable.

9. Turn the Transmission Analyzer II ON.

10. Check the program version listed on the startup screen. If the new version number appears on the startup screen, the unit is ready to use the updated program.

Service

If the 9U-7500 Transmission Analyzer II does not operate properly, perform the "Checking Analyzer for Proper Operation" test in this manual. If the analyzer is faulty, it can be sent to AVSpare Service Technology Group's Tool Repair. Tools that are less than one year old will be repaired under warranty (except for abuse). The cost of out-of-warranty repair will be charged to the owner.

When returning units to AVSpare's Tool Repair Service, be sure to enclose a letter that describes the problem and give the date of purchase. If the tool is out of warranty, include a Purchase Order Number with the shipment.

Send the tool to one of the CSTG addresses and mark it, "Attn: Tool Repair".

Electronically Actuated Pumps

The 9U-7500 Transmission Analyzer II now has the capability to test electronically actuated pumps installed on the hydraulic test bench. The analyzer controls these pumps by energizing the actuating solenoids inside the pump. CSTG has developed test procedures for these pumps using the Transmission Analyzer II. These test procedures are being added to NEHT5000 Bench Testing Hydraulic Components. If you have already obtained a copy of Bench Testing Hydraulic Components that doesn't have the test procedure for electronically actuated pumps; you will receive these test procedures in the mail.

Testing

Connecting Analyzer Test Cables To Transmission Solenoids

Connecting an analyzer test cable.

To connect an analyzer test cable to the transmission solenoids, use the following steps.

1. Disconnect the vehicle harness connectors from the solenoids of the transmission.

2. Select the test cable which has the same connector type as the vehicle harness connectors that have been disconnected.

NOTE: Match the letter and/or number of the test cable to the letter/number of the solenoid that is being tested. This letter/number is molded into the solenoid valve body.

3. Insert the 2-pin test cable connector into the solenoid connector.

4. Connect the 31-pin connector of the test cable into the analyzer or the 9U-7498 Extension Cable.

Solenoid Test

1. From the selected machine information screen, select "SOLENOID TEST", by pressing the "SOL TEST" key. This screen will appear.

2. Connect the cable called for on the transmission analyzer display (refer to previous section). Push "ENTER".

NOTE: When testing Challenger Tractors, there are more than three choices available on this screen. These choices allow you to perform certain functions, such as initializing two solenoids at the same time. They are on the Challenger menu to allow the necessary adjustments to be made to the transmission.

3. Press the number "2" key. This screen will appear.

4. Select solenoid number "1" by pressing the number "1" key. This screen will appear.

5. Push "ENTER" and this screen will appear.

These are the possible coil conditions:

COIL OPEN

COIL SHORTED

SOLENOID O.K.

RTN SHORTED TO GND

COIL SHORTED TO GND

INVALID SOLENOID #

OHMS OUT OF RANGE

6. To test solenoids automatically, press the "SOL TEST" key to return to this screen:

7. If the number "1" key is pressed, this screen will be displayed. The analyzer will cycle through the solenoids and it will continue to cycle until it finds a fault. At that time the analyzer will stop on the solenoid showing the fault and display the problem. This is a good method for finding intermittent faults.

Refer to Step 5 for the different coil conditions.

8. When finished with the "AUTO SOLENOID TEST", return to the "SOLENOID TEST MENU" screen by pressing the "SOL TEST" key. This screen will appear.

9. If the number "3" key is pressed, this screen will be displayed. The analyzer will prompt the operator to enter a solenoid number. It will then turn ON the selected solenoid. In this mode the analyzer only turns ON the solenoid and does not display a message stating a fault, if one should occur.

10. When finished with the "SOLENOID TEST SCREEN", return to the machine information screen by pressing the "MACH INFO" key. This screen will appear.

11. Stop here by turning OFF the Transmission Analyzer II or go to another test procedure.

Shift Lever Test

The transmission analyzer can be used to test switch assemblies and switch harnesses. However, the shift lever for models with the Autoshift Transmission control feature cannot be tested with the Transmission Analyzer II. These models have diagnostic features on the machine which check the shift lever functions.

1. From the selected "MACHINE INFORMATION" screen select "SHIFT LEVER TEST", by pressing the "SHIFT LEVER TEST" key. This screen will appear.

2. Select the cable adapters that are best suited for the transmission being tested. Connect the test cables to the machine harness connected to the solenoids. Push the "ENTER" key.

3. Move transmission gear selector lever in machine cab to desired gear (for example, 3F). This screen will appear.

4. With no gear shift lever connected to the analyzer, the display will show "GEAR SELECTOR PROBLEM".

5. When finished with the gear selector test, return to the main information screen by pressing the "MACH INFO" key. This screen will appear.

6. Stop here by turning OFF the Transmission Analyzer II or go to another test procedure.

Transmission Shift Test

1. From the selected machine menu, select the "TRANSMISSION TEST SCREEN", by pressing the "TRANS TEST" key. This screen will appear.

2. Connect the cable called for on the transmission analyzer display (refer to the "Connecting Analyzer Test Cables to Transmission Solenoids" section to connect cables from analyzer to transmission solenoids). Push "ENTER".

This screen shows that the Transmission Analyzer II is outputting a signal placing the transmission in "NEUTRAL". Enter the gear number and direction (for example, 1R, 1F, 2F, etc.) at the "ENTER GEAR" prompt; then press the "ENTER" key.

Exceptions: For ICM transmissions, Scrapers/Trucks and Articulated Trucks, there is no need to put in the number for direction unless there is more than one reverse gear or neutral.

Example: R, N, 1, 2, 3, etc. for 1 reverse and 1 neutral.

Example: 2R, 1R, N, 1, 2, 3, etc. for 2 reverses and 1 neutral.

Example: R, 2N, 1N, 1, 2, 3, etc. for 1 reverse and 2 neutrals.

NOTE: Always be aware of how many neutrals and reverses are in the transmission being tested. Shifting errors will occur if the wrong transmission is selected.

When the selected gear is entered, that gear number and direction will appear where the "NEUTRAL" appears in the display above. If a gear that is not valid for the selected machine is entered, a message stating "!!INVALID GEAR!!" will appear on the screen. This message will also be displayed if an "R", "N", or "F" is entered when not needed.

3. Continue to shift between different gears, stop testing, or go to a "Shift Lever Test".

a. To stop testing, or to go to a "Shift Lever Test", first leave the "TRANSMISSION TEST" mode by pressing the "MACH INFO" key.

b. If the transmission has not been shifted into "NEUTRAL", the analyzer will continue with the screen telling the operator to shift into "NEUTRAL". This screen will appear as follows.

4. Wait for transmission to stop and hit the "ENTER" key. This screen will appear.

5. Stop here by turning the Transmission Analyzer II OFF, or go to another test procedure.

Using The Transmission Analyzer With ICM (Individual Clutch Modulation) Transmissions

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Use of the Transmission Analyzer II can result in sudden movement of the machine, which can cause injury to persons on or near the machine. To prevent possible injury, use the procedure that follows before installing the Transmission Analyzer II.

Setup Instructions

For Wheel Tractor Scrapers Only, Follow Steps 1 through 5 and Then Steps 10 through 15.

1. Move the machine to a smooth, level location away from working machines and personnel. Put the transmission shift lever in the Neutral position. Stop the tractor and scraper engine(s).

2. Activate the parking brake. Lower the bowl to the ground. Lower the apron to the ground.

3. Move the cushion-hitch (and bail) control lever to LOCK DOWN/BAIL DOWN position. Make sure the bail (if equipped) is down. Make sure that the rear bracket assembly of the hitch is down and against (resting on) the front hitch assembly.

4. Remove both axles from the tractor or scraper, whichever one is being tested.

5. Permit only one operator on the machine. Keep all other personnel away from the machine and/or in the view of the operator.

For Off-Highway Trucks Only, Follow Steps 6 through 15.

6. Move the machine to a smooth, level location away from working machines and personnel. Put the transmission shift lever in the NEUTRAL position.

7. Activate the parking brake. Raise the body (bed) and install the body retaining pins. Stop the engine. DO NOT move the hoist lever to the LOWER, FLOAT, or RAISE position while the engine is in operation.

8. Remove both drive axles.

9. Permit only one operator on the machine. Keep all other personnel away from the machine and/or in view of the operator.

Steps 10 through 15 Are for Wheel Tractor Scrapers and Off-Highway Trucks.

10. Install the 9U-7500 Transmission Shift Analyzer II cables between the Analyzer and the transmission.

11. Turn the engine ON and run at low idle speed only.

12. Operate the engine until oil is at normal operating temperature. Cold oil may give incorrect results.

13. Perform a NEUTRAL to 1st shift with the transmission analyzer.

14. Check the rotary switch assembly position by going to the "Shift Lever Test" and verifying that the switch is in 1st gear. For the 4/8 SPD, the LOCKUP solenoid should be turned ON.

15. Go back to the Transmission Test screen and perform a 1st to Reverse shift.

16. Check the rotary switch assembly position by going to the "Shift Lever Test" and verifying the switch is in Reverse gear. For the 4/8 SPD, the LOCKUP solenoid should be turned ON.

NOTE: If the transmission takes too much time making its shifts, the Transmission Shift Analyzer II will display a message saying, it is "SHIFTING SLOW". If it takes too long to shift between gears, return the transmission to NEUTRAL and turn the engine OFF.

17. Use the Transmission Shift Analyzer II to return to NEUTRAL.

18. Failure of the transmission to pass this test sequence indicates mechanical or hydraulic problems within the transmission, or an intermittent electrical problem.